Compressible Supports for Installation of Shower and Bath Fixtures and Systems and Methods Thereof

ABSTRACT

Disclosed herein are methods for installing bases and supports for shower and bathtub fixture components in a level and secure manner. Compressible supports, and templates and fixture bases comprising the compressible supports to aid installation are also contemplated herein.

CROSS REFERENCE TO RELATED APPLICATION

This application is a non-provisional application of U.S. ProvisionalApplication No. 63/077,203, filed on Sep. 11, 2020, the disclosure ofwhich is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Installations of prefabricated bathroom fixtures often do not result ina leveled shower base due to inconsistencies in the building structureto which the fixture is secured. Additionally, such fixtures aretypically flexible to some degree and require additional support beneaththe fixture base to prevent flexing of the shower base. Flexing of thefixture base may ultimately result in cracking and failure of thefixture.

Manufacturers have sought to resolve these issues by providingsupported, pre-leveled shower bases. However, such shower bases rely onthe subflooring being level for a level installation, as the integratedpre-leveled supports are provided in reference to an assumed level andconsistent surface. As stated above, this is often not the case.

Installation contractors have also attempted to provide a levelsupported installation by installing supports for the fixture basedirectly to the subfloor at installation.

For example, contractors commonly embed the fixture base within a newlypoured mortar base pressed between the base and the subfloor and securethe fixture base in a leveled position as the mortar cures. However, themortar layer is prone to separate from the bottom surface of the fixturebase as the mortar cures due to compression forces during installation,settling of the mortar, and shrinking of the mortar as it cures.Separation of the mortar from the fixture base results in gaps betweenthe fixture base and mortar layer. The presence of gaps undermines thesupport for the fixture base and allows the fixture base to flex againstthe hardened mortar layer and cause scraping noises during use. Repeatedscraping over extended use can potentially damage the fixture base.

Use of self-leveling concrete alleviates these issues to some degree butrequire additional cost and expertise in their application. Moreover,self-leveling concrete is limited in its application to the upperstories of wood-framed structures due to building requirements and firecodes.

It has also been attempted to shim the fixture base during installationto provide supports within the gap between the shower base and frame.However, as for the mortar layer method described above, the piles offoundation material may shift during installation, use, and repair, andtherefore do not provide adequate or reliable support for the fixturebase.

It is a purpose of the invention disclosed herein to provide improvedmethods for installations of showers and bathtub bases. It is also apurpose of the invention to provide convenient supports, systems, andfixture bases to aid the improved installation methods.

SUMMARY

Compressible supports are disclosed herein for use in installationmethods and generally can comprise a support cavity for receiving acurable foundation material. Fixture bases and other fixtureinstallation systems comprising the compressible supports are disclosedherein that incorporate compressible supports into installation methodsand offer improvements over conventional installation methods.

Also disclosed herein are methods for installing a fixture base to abuilding structure comprising providing a compressible support adjacenta building structure, wherein the compressible support comprises acurable foundation material; securing the fixture base to the buildingstructure such that the compressible support contacts the buildingstructure and a surface of the fixture base; and allowing the curablefoundation material to cure.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts a shower base being installed over mortar poured directlyto the subfloor, according to a conventional installation.

FIG. 2 depicts an embodiment of a compressible support of the presentinvention.

FIG. 3 depicts a fixture base installation system according to thepresent invention.

FIG. 4 depicts a fixture base according to the present invention.

DEFINITIONS

The phrase “a” or “an” entity as used herein refers to one or more ofthat entity.

References to items in the singular should be understood to includeitems in the plural, and vice versa, unless explicitly stated otherwiseor clear from the context. Grammatical conjunctions are intended toexpress any and all disjunctive and conjunctive combinations ofconjoined clauses, sentences, words, and the like, unless otherwisestated or clear from the context. Thus, unless otherwise indicated ormade clear from the context, the term “or” should generally beunderstood to mean “and/or” and, similarly, the term “and” shouldgenerally be understood to mean “and/or.”

Recitation of ranges of values herein are not intended to be limiting,referring instead individually to any and all values falling within therange, unless otherwise indicated herein, and each separate value withinsuch a range is incorporated into the specification as if it wereindividually recited herein.

The words “about,” “approximately,” or the like, when accompanying anumerical value, are to be construed as indicating a deviation as wouldbe appreciated by one of ordinary skill in the art to operatesatisfactorily for an intended purpose. Ranges of values and/or numericvalues are provided herein as examples only, and do not constitute alimitation on the scope of the described embodiments. The use of any andall examples, or exemplary language (“e.g.,” “such as,” or the like)provided herein, is intended merely to better illuminate the embodimentsand does not pose a limitation on the scope of the embodiments or theclaims. No language in the specification should be construed asindicating any unclaimed element as essential to the practice of theembodiments.

In the following description, it is understood that terms such as“first,” “second,” “third,” “upper,” “lower,” “below,” “top,” “bottom,”and the like, are words of convenience and are not to be construed asimplying a positional or chronological order or otherwise limiting anycorresponding element unless expressly stated otherwise.

The information that follows details various embodiments of thedisclosure. For the avoidance of doubt, it is specifically intended thatany particular feature(s) described individually in any one of theseparagraphs (or part thereof) may be combined with one or more otherfeatures described in one or more of the remaining paragraphs (or partthereof). In other words, it is explicitly intended that the featuresdescribed below individually in each paragraph (or part thereof)represent aspects of the disclosure that may be taken in isolationand/or combined with other aspects of the disclosure. The skilled personwill appreciate that the claimed subject matter extends to suchcombinations of features and that these have not been recited in detailhere in the interest of brevity.

As defined herein, the term “compressible” generally encompasses thosestructures and materials that can accommodate a compression force byaltering a dimension of the structure. While it may be technicallyaccurate to consider all structures as compressible to a degree, for thepurposes of this disclosure compressible will refer to those structureshaving a dimension able to be deformed by at least about 5% withoutcausing damage to the structure. Compressible supports also encompassrepeatedly compressible structures that include materials able to becompressed by a compression force as defined herein and expand to theiroriginal dimensions or a portion thereof upon relief of a compressionforce. In some aspects, the repeatedly compressible structures canreceive a compression force in a range from 1 psi to 100 psi, and expandto at least 70%, at least 80%, at least 90%, or at least 95% of itsoriginal dimension upon relief of the compression force.

As defined herein, the term “curable” in reference to a foundationmaterial, or material in general, refers to a material that exists in afirst amorphous state (e.g., liquid, gel, particulate flow) beforehardening into a structure having fixed dimensions. In this sense, mixedcement can be considered as a curable foundation material in its mixedstate, and as a cured foundation material once hardened into a fixeddimension. Generally, the curing of curable foundation materialscontemplated herein represent an irreversible chemical change orphysical process (i.e. formation of a durable lattice structure).However, in certain aspects, the curable materials can encompassmaterials that undergo a reversible transition, where the material hasfixed dimensions under conditions typical of installation and use.Water, therefore, may not be considered a curable foundation material bythe context of this disclosure, as frozen water does not persist at roomtemperature. In contrast, thermoplastic polymers may be considered as acurable foundation material upon heating to its melting point, as themelted polymer will return to a solid state with fixed dimensions atroom temperature.

With respect to “filling” an internal cavity, the term “filled” asreferred to herein means filled to any degree that prevents disruptionsin continuity of the foundation material along the height dimension ofthe cavity.

Cavities are described herein as retaining the foundation material tosupport the fixture base. For the purposes of this disclosure, a“cavity” refers to gaps within a three-dimensional profile of thesupport having a volume of at least 1 mL. In this sense, the cavities asreferred to throughout the specification do not encompass microsphereshaving a very small internal volume (e.g., ˜μL) such as are commonlypresent within foamed materials.

DETAILED DESCRIPTION OF THE INVENTION

The information that follows describes embodiments with reference to theaccompanying figures, in which preferred embodiments are shown. Theforegoing may, however, be embodied in many different forms and shouldnot be construed as limited to the illustrated embodiments set forthherein.

FIG. 1 depicts a conventional installation of fixture base 10 tobuilding structure 16. As shown, a mortar layer 18 is provided directlyto subfloor 16 to fill the gap between subfloor 16 and a bottom surfaceof fixture base 10. Fixture base 10 is secured to the subfloor 16 bylaying the fixture base 10 into the uncured mortar layer 18 and applyingappropriate fasteners to the fixture base and subfloor. Rigidstabilizing fins 12 and recesses 14 are provided to allow the mortarlayer 18 to maintain contact with the fixture base 10 duringinstallation, as the mortar 18 hardens. Such methods have not beeneffective in eliminating gaps between the bottom surface of fixture baseand the mortar layer. Thus, fixture base 10 will flex against mortarlayer 18 during use, resulting in noise and damage to the fixture base.

Compressible supports are disclosed herein that address issues ofconventional installations. FIG. 2 depicts a compressible support 20 ofthe present invention, having a top surface 22 and a bottom surface 24.Support 20 comprises a central cavity 26 that extends from top surface22 to bottom surface 24. Cavity 26 can be filled with a foundationmaterial 18. In contrast to the conventional method shown in FIG. 1,positioning the filled compressible support 20 between the subfloor andthe bottom surface of the fixture base provides a pillar of foundationmaterial within cavity 26. Optionally, the support 20 can comprisefasteners 28 for securing the support directly to subfloor 16. As shown,the foundation material can be maintained in constant and solid contactwith the bottom surface of the fixture base during dynamic compressionforces. Alternatively, support 20 also can be provided with optionalcavity cap 29, shaped to seat within cavity 26 and seal the foundationmaterial within the cavity. By capping and sealing the foundationmaterial within the cavity, the volume of the cavity 26 can bemaintained by allowing the shape of the cavity to flex according tocompression forces applied to the fixture base during installation.

More generally, the compressible supports disclosed herein can becompressible and/or expandable against a compression force. Repeatedlycompressible supports allow the support to largely return to itsoriginal shape following a dynamic compression load while the foundationmaterial cures. In this manner, flexing of the bottom surface of afixture base during installation when the foundation material is notcured and malleable, does not cause the foundation material to losecontact with the fixture base. Rather the foundation material ismaintained against the fixture base during dynamic compression forcesapplied to the fixture base during installation. After installation ofthe fixture base is complete, the foundation material can be allowed toharden while the compressible support maintains the foundation materialagainst the fixture base, without gaps resulting from the dynamiccompression forces.

Supports contemplated herein can be at least partially compressible byreducing at least one dimension (e.g., height) upon application of acompression force to the compressible support. It is also contemplatedthat the compressible support can resist compression beyond a certainamount of compression, or on the application of a compression force thatexceeds a certain load maximum. For instance, the compressible supportcan be compressible to a range of not more than 40%, 50%, 60%, 70%, 80%,90%, or 95% of its uncompressed height. In other aspects, thecompressible support may be able to accept a compression force (bycompression) in a range from 1 to 100 psi, from 1 to 50 psi, from 1 to20 psi, from 1 to 10 psi, from 1 to 5 psi, or from 0.1 to 10 psi.

In embodiments wherein the compressible support is expandable againstthe compression force, the support can be capable of withstanding anycompression force, or amount of compression disclosed above, to anyportion of the original dimension of the support. In certainembodiments, the support may be returned to at least 40%, at least 50%,at least 60%, at least 80%, at least 90%, at least 95%, or at least 100%of its original height after relief from the compression force. Certainaspects may be repeatedly compressed by a compression force and expandedupon relief of the force for any number of repetitions and duration, aswould be understood be a person of ordinary skill in the art.

Compressible supports disclosed herein are not limited to any particularcomposition, and generally can comprise any material that allows thesupport to be compressed. In certain aspects, compressible supportscontemplated herein can comprise plastics such as vinyls (e.g.,polyvinyl chloride), polystyrene, polyethylene, phenolics, silicones,cellulose acetate, and urethanes. In certain embodiments thecompressible support can comprise a foamed material, an extrudedmaterial, a molded material, or any combination thereof. Where thesupport comprises a foamed material, the foamed material can comprise anon-porous foam suitable to retain a liquid foundation material within acavity in the support. It is also contemplated herein that thecompressible support may comprise further additives and adjuvants aswould be understood by those of ordinary skill in the art. For instance,in certain embodiments, the compressible support can comprise a foamedmaterial comprising microsphere additives to improve and expandabilityof the foamed material against dynamic and variable compression forces(e.g., during installation). In certain aspects, the compressiblesupports contemplated herein can comprise a repeatedly compressible, orexpandable, material (e.g., a memory foam) that allows the support tofully or partially return to an original shape upon relieving acompression force. Other materials suitable for construction of thecompressible support are also contemplated herein, as would beunderstood by a person of ordinary skill in the art.

Cavities with the supports disclosed herein are not limited to anyparticular size and generally can take any form that allows the cavityto contain a desired amount of a curable foundation material. In certainaspects, the cavity can have a volume of at least 5 mL, at least 10 mL,at least 25 mL, at least 100 mL, or at least 500 mL. In other aspects,the cavity can have a volume in a range from 1 mL to 1L, from 5 mL to500 mL, or from 25 mL to 250 mL. In this sense, it may be seen that thecavity can comprise a relatively significant amount of volume within thesupport. In certain aspects, a ratio of the support volume and thecavity volume can be in a range from about 100:1 to about 1:10. Thus, incertain aspects, the support can approach a cup shape where the cavityin the support represents the major portion of the compressible support.

The shape of cavities in the compressible supports contemplated hereinis not limited to a particular shape and generally can comprise anyshape suitable to support the foundation material during curing. Incertain aspects, cavities contemplated herein can comprise cavitieswithin supports contemplated herein may be cylindrical (e.g., a toroidalcylinder), and extend through the support from one surface to anopposing surface. Cavities contemplated herein may be a rectangularprism. Cavities contemplated herein can have a constant or variablecross-section through the length of the cavity. For instance, cavitiescontemplated herein may have a square, rectangular, circular, oval,triangular, or star-shaped cross-section at any point along the heightof the cavity. In certain aspects the cavity can be shaped such that abottom portion of the cavity is wider than a top portion of a cavity(e.g., conical, pyramidal).

Supports contemplated herein can comprise a plurality of cavities. Insome aspects, the support can comprise at least 4, at least 6, at least12, or at least 24 cavities. Other aspects can comprise 3 to 18cavities. Aspects contemplated herein can comprise a plurality ofcavities within a single support, the amount of cavities based on thesize of the support itself. For instance, supports contemplated hereinmay have an amount of cavities based on the surface area of the support,e.g., about 1 per 4 in², about 1 per 8 in², or about 1 per 12 in². Inthis manner a single support may be provided which positions severalcavities about the footprint of an intended fixture installation. Thecavities may be evenly spaced or provided in reference to the counter offixture base, as discussed relative to the fixture base installationsystems below.

Supports contemplated herein can comprise cavities that extendcompletely through the support, from a top surface to a bottom surface.In this manner, a curable foundation material can be poured into thesupport and contact the same surfaces that contact the top and bottomsurfaces of the compressible support. Cavities may also extend partiallythrough the support, for instance from a top surface to a midpointwithin the support. In such instances, the portion of the supportbetween the opposing surface and the cavity wall can comprise anon-compressible material, such that can resist significant compressionforces.

Thus, it can be seen that the compressible supports disclosed herein mayreceive a repeated, variable, and dynamic compression force, and quicklyreturn to its original shape to support the fixture base in anoriginally secured and level position. In this manner, the cavity can berepeatedly compressed and expanded to an original position as thefoundation material cures, while also limiting the amount of thefoundation material required to fill the cavity. Such arrangements canalso prevent contact between the foundation material and the surface ofthe building structure and preventing the foundation material fromleaking along the bottom surface of the support. Supports comprising acavity that does not extend through a bottom surface of the support canalso provide more efficient repairs, as the foundation material does notcontact the building structure itself. The support can be removed fromthe building structure without effort, or by relieving a separateattachment means securing the support to the building structure, such asany attachment means described herein.

Further still, the cavity can be an internal cavity enclosed completelywithin the support. In such aspects, the cavity can be prefilled with afoundation material, the foundation material being activatable during orprior to installation to initiate a curing process. As a non-limitingexample, the prefilled foundation material can comprise a polymericresin and an activator configured to be released within the polymericresin upon compression of the support and internal cavity. In suchaspects, the internal cavity may comprise a capsule within the support,breakable upon compression of the support, the cavity, or both. Similarto supports comprising cavities extending partially through the support,supports contemplated herein comprising internal cavities can comprise anon-compressible supporting portion adjacent each of the top and bottomsurfaces of the internal cavity and extending to the bottom and topsurfaces of the support, respectively. In this manner, the foundationmaterial can be completely restricted within the support and fromcontacting the building structure or fixture base to be installed.Still, such embodiments allow the support to be compressed and exert areturning expansion force against the compression force to return thesupport to an original position once the compression force is relieved,thereby allowing the foundation material to cured in a form thatprovides complete support to the fixture base.

Securing the support between the building structure and the fixture basecan be accomplished by adherence of the foundation material to theindividual structures during installation. However, additional and/orseparate attachment mechanisms are also contemplated herein. Forinstance, fasteners (e.g., nails, screws, etc.) can be driven throughthe support and into the subfloor to retain the support directly inposition relative to the subfloor. Clips are also contemplated, toconnect the top surface of the support with a complementary feature onthe bottom surface of the fixture base, for example. In certain aspects,adhesives can be applied, or pre-applied to the top and bottom surfacesto attach the support to the fixture base and/or building structure,respectively. Certain embodiments also can comprise means for attachingthe supports to the building structure, the fixture base, or both. Anyother combination of latches, adhesives, fasteners, and the like arealso contemplated herein, as would be understood by a person of ordinaryskill in the art.

In certain embodiments, the cavity can be configured to retain anyfoundation material disclosed herein, particularly while in an amorphousliquid or gel form. In certain aspects, the support can comprise acapping seal to seal a portion of the cavity once filled with foundationmaterial. Additionally, or alternatively, the cavity can comprise acavity liner of different material than the body of the support. Wherethe foundation material comprises a polymeric material, such cavityliners resistant to dissolving on contact of non-polar substances canprotect the structural integrity of the support and ensure thefoundation material is contained within the cavity. Further, cavityliners may preserve the volume of the cavity as the foundation materialcures, to ensure that the foundation material cures in a position thatfully secures and supports the fixture base, and ensuring that nosubstantial gaps are formed between the building structure and thefixture base throughout the span of the foundation material. In certainaspects of the invention, the cavity may be shaped to allow the cavityto expand horizontally under a vertical compression force, such that thevolume of the cavity remains substantially constant throughoutcompression of the support. As a non-limiting example, the support cancomprise compressible foam surrounding a rubber-lined cavity wherein thecavity comprising accordion-shaped walls.

In certain embodiments, a deviation of the volume of the cavitythroughout a compression of the support can be less than about 50%, lessthan about 40%, less than about 30%, less than about 20%, less thanabout 10%, or less than about 5% relative to the original volume.Sealing the cavity may also allow the compression force to betransferred from the foundation material within the cavity to thecompressible support such that the cavity volume is maintained. Anydeviation disclosed herein is contemplated for compressions of theheight of no more than 40%, no more than 60%, no more than 80%, no morethan 90%, or no more than or at least 95% of the original height of thesupport.

FIG. 3 depicts an installation system of the present invention thatincorporates a plurality of compressible supports 20 at severalpositions along a membrane layer 30. Membrane layer 30 provides atemplate for positioning compressible supports 20 and provides a seal tothe bottom surface of the support 20 and associated cavity. In thismanner, the cavity is sealed and contact between the foundation material18 and subfloor 16 is prevented.

Generally, fixture base installation systems contemplated herein cancomprise a membrane layer and a plurality of the compressible supportsof the present invention. Compressible supports of the systemscontemplated herein can be the same or different, regarding any of theconsiderations discussed above (e.g., shape, size, composition, etc.).The membrane layer is not limited to any particular material and can beany that are compatible as an underlayment to the compressible supportsand installation processes disclosed herein. In certain aspects, themembrane layer can comprise a top surface configured to receive thecompressible supports and a bottom surface configured to seat againstthe building structure. The membrane layer can comprise a footprint thatis substantially equivalent to a fixture base to be installed. Incertain aspects, the membrane layer can be a square or rectangularshape.

The membrane layer can be flexible or rigid. The membrane layer can besubstantially planar or contoured to a particular shape. As for thecompressible supports, the membrane layer can also be somewhatdeformable along its bottom surface (opposite the compressible supports)to accommodate irregularities in the building structure. Thus, incertain embodiments, the membrane layer can comprise a cellulosic layer(e.g., paper wood, cardboard, etc.), a felt layer, a silicon layer, afoam layer, or any combination thereof.

Systems contemplated herein can comprise compressible supports fixed tothe membrane layer in a permanent or removable manner. The compressiblesupports may be pre-fixed to the membrane or configured to be attachedat the time of installation. For systems comprising removable attachmentof the compressible supports, markings may be provided on the membranelayer indicating an advantageous, proper, or preferable arrangement ofthe compressible supports. Markings on the membrane layer can take anyform as would be understood by those of skill in the art, for examplecross-hatching, grid overlay, or any other marks at predeterminedlocations.

It is also contemplated that the systems can be designed to complementexisting fixture base designs that are commonly installed. Thus, incertain aspects the top surfaces of any or all of the compressiblesupports of the systems may be specially contoured to accommodate thecontour of a particular fixture base. Such contouring can allow thefoundation material within the support to better contact the surface ofthe fixture base and allow a more even compression of the support.Contouring of the top surfaces of the compressible supports may alsoprovide additional guidance to placement of the fixture base withrespect to the compressible support, membrane layer, and buildingstructure.

The membrane layer can be attached to the building structure and cancomprise any attachment means as discussed above for securing themembrane layer in position. As a non-limiting example, fasteners driventhrough compressible supports as mentioned above can also be extendedthrough the membrane layer into a subfloor to retain each in position.Alternatively, fasteners can be driven through the membrane layerseparately from the compressible supports.

Fixture bases comprising the compressible supports are also contemplatedherein. FIG. 4 depicts a fixture base with the compressible supportsshown as toroidal cylinder supports 44 within recesses 42 and adjacent abottom surface of the fixture base 40. Each of supports 44 comprises acapped cavity 46 filled with foundation material 18. As for theinstallation system depicted by FIG. 3 and discussed above, thecompressible supports can be provided at spaced intervals relative tothe fixture base 40. By providing the supports 44 in direct attachment(or configured to be being directly attached) to the fixture base theexact contours of the bottom surface of the fixture base can be moreeasily matched by the top surface of the support. As the support iscompressible, exact dimensions of the compressible supports are notrequired, and thus may extend somewhat beyond a bottom dimension of thefixture base, with the bottom surface of each support configured to besubstantially horizontal as installed. It can thus be seen thatcompressible supports herein may be designed according to any specificfixture base, such as those currently marketed, and instantly improvethe quality of the products as installed.

Compressible supports can be spaced and arranged to contact the fixturebase as discussed above. In certain aspects, the compressible supportsmay also be removable from the fixture base. For example, recesseswithin the bottom surface of the fixture base can be shaped to retain acompressible support. Compressible supports may be retained within therecesses by adhesives applied prior to installation, or by snug fitdesign of the supports and recesses. In certain aspects, supports havinga seal or cap along the bottom surface can be filled with foundationmaterial prior to securing to the support to the fixture base.Alternatively, the support can be fixed to the fixture base (e.g.,placed within a recess) and the support can be filled in an invertedposition as the cavity within the support is filled. After filling thecavity with the foundation material, a cap or seal may be applied toclose the cavity, and the fixture base may be returned to an uprightposition while retaining foundation material within the cavity.

Fixture bases contemplated herein are not limited to any singular type,or group of fixtures, and can be generally any that have a surfacecapable of flex to some degree, particularly during conventionalinstallation methods. The present invention can thus apply toinstallation of showers, bathtubs, sinks, tiled surfaces, wash basins,wall mounted devices, and foundation components thereof. Problems ofconventional installations noted above can be particularly problematicfor fixtures where significant compression forces are applied to a baseof the structure during consistent repeated use. In certain aspects,installation of fixture bases can refer to the installation of a showertray, a bathtub, and foundation components thereof.

Also disclosed herein are methods for installing fixtures in a level andsecure manner that is not dependent on the condition of the surface towhich the fixture is installed. Methods disclosed herein also canwithstand the rigors of installment, i.e., any pressures and adjustmentsapplied to the fixture components during installation. Adjustments andsettling during installation often can be the cause of displacing mortarpillars, piles of foundation material, and the like, which result ingaps between the surface of the bath fixture and the mortar support.Gaps created between the support and the fixture surface then allow thefixture surface to flex under application of weight to the surface.Flexing of shower bases and bathtub fixtures is a common issue, andcommonly measured as the deflection of the surface under 300 psi,according to the relevant ASTM codes.

Methods are disclosed herein for installing a fixture base to a buildingstructure. Methods contemplated herein can comprise (a) providing acompressible support adjacent the building structure, wherein thecompressible support comprises a curable foundation material; (b)securing the fixture base to the building structure, wherein the fixturebase is adjacent to the compressible support; and (c) curing the curablefoundation material.

The compressible supports of methods disclosed herein refer to any ofthose disclosed above. As will be understood by those of skill in theart, the building structure is also not limited to any particularmaterial or shape and can be any to which installation of fixture baseis desired. The building structure may be in any location within thebuilding. In certain aspects the building structure is on a first,second, third, fourth, or fifth floor of a building. In other aspects,the building structure can be located within a basement, a kitchen, abathroom, or a mud room, of a building. The building structure can beany portion of the building, such as the wall, ceiling, floor, subfloor,or any finished or unfinished stage of the building structure. Thebuilding structure can be in any condition suitable to support thefixture to be installed, and comprise any material such as wood, metal,composites, and the like. As a non-limiting example, building structurecan comprise a wooden subflooring within a second story master bathroom.Alternatively, the building structure can be a basement mortar floor.

Providing a compressible support adjacent the building structure cancomprise manually placing the compressible support directly on thesubflooring. In such aspects, providing the support can further compriseattaching the compressible support directly to the building structure.The compressible support can be attached by any of the attachment meansdisclosed above. It is also contemplated that the compressible supportmay be provided as part of an installation systems as described above ascomprising a membrane layer and plurality of compressible supports. Insuch aspects, providing the compressible support adjacent the buildingstructure can comprise, or consist of laying the membrane layer directlyupon the building structure. In this manner, the compressible supportcan be considered adjacent the building structure through contact withthe membrane layer. Providing the compressible support can also beachieved by a compressible support (or series of compressible supports)attached to the bottom surface of a fixture base, as disclosed above. Asfor installation systems comprising a membrane layer, compressiblesupports can be considered as being adjacent the building structurethrough contact with any caps, seals, or films present between thecompressible support and the building structure.

In certain aspects, providing a compressible support can compriseproviding a support prefilled with a foundation material. Alternatively,providing a compressible support can comprise adding a curablefoundation material within the cavity of the compressible support. Insuch aspects the foundation material may be added to the top or bottomof the cavity, as described above for installation systems comprising amembrane layer and fixture bases, respectively. Alternatively, thecompressible supports may be filled as positioned directly on thesubfloor through a top opening in the cavity. Where the supportcomprises an internal cavity, the foundation material may be injected,or the cavity may be broken, filled, and resealed. As described above,filling the cavity with foundation material or adding foundationmaterial to the cavity can comprise adding any amount of foundationmaterial to the cavity. In some aspects, adding foundation material cancomprise adding an amount of foundation material to the cavity greaterthan 40%, 50%, 60%, 70%, 80%, 90%, 95%, or 100% of the volume of thecavity.

The curable foundation material is not limited to any particularmaterial and can be any material that is suitable to remain amorphousduring the installation phase, and to provide fixed support to thefixture base as it hardens. Curable foundation materials as contemplatedherein therefore can include cement, concrete, mortar, thin set, and thelike. Curable foundation materials also can include polymeric materialsformed by the polymerization of resins as activated by an activator.Polymeric resins can include polyester resins, vinyl resins, and epoxyresins. Activators can generally include peroxides and other radicalactivators, for example methyl ethyl ketone peroxide. Other resins andactivators are also contemplated herein, as would be understood by thoseof ordinary skill in the art.

Once the compressible supports are provided adjacent the buildingstructure as discussed above, the fixture base can be secured to thebuilding structure as the foundation material cures. In certain aspects,securing the fixture base to the building structure may comprise layinga bottom surface of the fixture base on the top surface of thecompressible support(s). Securing the fixture base can further compriseleveling the fixture base, fastening the fixture base to the buildingstructure with fasteners, applying adhesives to the fixture bases,applying caulk compounds within the joints between the fixture base andthe building structure, securing additional fixture components to thefixture base, or any combination thereof, and in any order. As for theproviding the support adjacent the building structure, securing thefixture base adjacent the compressible support encompasses embodimentswhere a cap, seal, membrane layer, or a non-compressible member betweenthe support and the fixture base. For the purposes of this disclosure,such installations can be considered adjacent even when not in directcontact, so long as a compression force applied to one element may beefficiently transferred to the adjacent element.

Securing the fixture base as described above can occur within (e.g.,less than) a curing time of the foundation material. In some aspects,the curing time of the foundation material can be less than about 8hours, less than about 4 hours, less than about 2 hours, less than about1 hour, or less than about 30 min, The curing time can be dependent onthe composition of the foundation material, and also can be dependent onenvironmental conditions (e.g., humidity, temperature) at the time ofinstallation. Thus, it is contemplated herein that curing time can be ina range from 30 min to 8 hours, from 2 hours to 4 hours, or from 1 hourto 12 hours. In certain aspects, it is contemplated that securing thefixture base can be completed much faster than the curing time, e.g., 1hour, 2 hours, 3 hours, 4 hours less than the curing time, to allow theinstaller sufficient time before the foundation material cures.

Curing the foundation material can comprise generally any method thattransforms the amorphous material into a hardened shape with fixeddimensions. The curing step can occur simultaneously with the securingstep disclosed herein, and thus can comprise simply allowing the curingtime to lapse. In other aspects, the curing step can comprise the timedrelease of materials into the foundation material, and or mixing ofcuring additives into the foundation material. Curing the foundationmaterial also can comprise applying energy to the foundation material,such as in the form of ultraviolet light or heat.

Securing the fixture base can comprise maintaining a compression forcebetween the fixture base and the compressible supports. In this manner,the compressible supports remain partially compressed throughout theinstallation, and curing time of the foundation material. As anon-limiting example, it is contemplated that the bottom surface ofcompressible supports secured to a fixture base may extend somewhatbeyond (e.g., ⅛ inch, ¼ inch, ½ inch, 1 inch) the fixture base itself.Once the fixture base is secured to the building surface, thecompressible supports will remain somewhat compressed to ensure goodcontact between the compressible support and the building structure andthe fixture base.

Methods disclosed herein can provide a level fixture base irrespectiveof the condition, angle, or irregularities present on a buildingstructure. It is also contemplated that the methods disclosed herein canminimize or eliminate the deflection of the fixture base commonlyobserved from conventional installations. In certain aspects, deflectionof the installed fixture base at 300 lbs, according to ANSI standardtesting, can be less than about 10 mm, less than about 5 mm, less thanabout 3 mm, less than about 2 mm, less than about 1 mm, less than about0.5 mm, less than about 0.1 mm. In other aspects, the deflection at 300lbs. can be in a range from about 1 mm to about 25 mm, from about 1 mmto about 10 mm, or from about 1 mm to 5 mm.

What is claimed is:
 1. A compressible support for the installation of afixture base to a building structure, the compressible supportcomprising: a compressible material configured such that a compressibledimension of the support is reduced to a compressed dimension byapplying a compression force to the compressible support, wherein thesupport expands to at least a portion of the compressible dimension uponrelief of the compression force.
 2. The compressible support of claim 1,wherein the compressible material is a foam.
 3. The compressible supportof claim 3, wherein the foam is a non-porous foam.
 4. The compressiblesupport of claim 3, wherein the foam is a memory foam.
 5. Thecompressible support of claim 1, further comprising an adhesive forattaching the compressible support to a membrane layer, a fixture base,or subfloor.
 6. The compressible support of claim 1, wherein thecompression force has a maximum compression force is in a range fromabout 0.1 psi to about 100 psi.
 7. The compressible support of claim 1,wherein the compressed dimension is in a range from about 60% to 90% ofthe original height of the support.
 8. The compressible support of claim1, wherein the compressible support is configured to receive a curablefoundation material.
 9. The compressible support of claim 8, wherein thecurable foundation material comprises a concrete, mortar, cement, clay,polymeric resin, or any combination thereof.
 10. The compressiblesupport of claim 8, wherein the compressible support comprises a supportcavity to receive the curable foundation material.
 11. The compressiblesupport of claim 10, wherein the support cavity extends through thecompressible support, from a first surface of the compressible supportto an opposite surface of the compressible support.
 12. The compressiblesupport of claim 10, wherein the support cavity has a volume in a rangefrom 5 mL to 500 mL.
 13. A fixture base comprising the compressiblesupport of claim
 1. 14. A fixture base installation system comprising: amembrane layer; and a compressible support comprising a cavity.
 15. Thesystem of claim 13, wherein the membrane layer comprises a paper layer,a felt layer, a silicon layer, or any combination thereof.
 16. Thesystem of claim 13, wherein the membrane layer comprises markingsindicating preferred positioning for the compressible support.
 17. Thesystem of claim 13, wherein the system comprises an adhesive to securethe membrane layer to a building structure, an adhesive to secure thecompressible support to the membrane layer, or both.
 18. The system ofclaim 13, wherein the system comprises a plurality of compressiblesupports.
 19. The system of claim 13, wherein: a bottom surface of thecompressible support is substantially planar; and a top surface of eachcompressible support is contoured to complement the bottom surface of afixture base at a support position.
 20. A method for installing afixture base to a building structure comprising: positioning acompressible support comprising a curable foundation material in contactwith the building structure at a first end of the compressible supportalong a compressible dimension; positioning the fixture base in contactwith the compressible support at a second end of the compressiblesupport along the compressible dimension; securing the fixture base tothe building structure; and curing the curable foundation material.